INCREASING THE DURABILITY OF PUMP UNITS USED IN IRRIGATION SYSTEMS BY COMBINED ENVIRONMENTALLY SAFE TECHNOLOGICAL METHODS
Abstract
The article analyzes the current state of reclamation agriculture. In order to increase the reliability and durability of pumping units (PU) used in irrigation systems, the technology of manufacturing and repairing the surface layers of the centrifugal pumps (CP) rotor shafts necks under sliding bearings (SB) and the landing surfaces of parts that are assembled with tension has been improved by using ecologically and technologically safe technologies of electrospark alloying (ESA), surface plastic deformation (SPD) and application of metal-plastic materials (MPM). At the same time: a) a new method of cementing their surfaces using the ESA method was developed and tested, which improves the quality parameters of the surface layer; b) a new method of forming sulfomolybdenum coatings using the ESA method was developed and tested, the surface layer of which contains up to 5 % molybdenum disulfide. A new method of forming wear-resistant coatings of Al-C-B composition on the bearing necks of CP rotor shafts by the ESA method has been developed, in which the microhardness of both the "white" layer and the diffusion zone increases with increasing discharge energy (Wр): at Wр=0.13 J – Нμ = 6487 MPa, and at Wp = 4.9 J – 12350 MPa. To improve the technology of restoration of the surface layer of the shaft, a new method is proposed, which includes the cementation operation by the ESA method, which is accompanied by the supply of nitrogen to the doping zone, which is a nitrocementation process in which the microhardness increases from 10,500 to 10,600 MPa and the depth of the increased hardness zone from 120 to 150 μm. and the surface roughness Ra also decreases, from 0.7 to 0.6 μm. A physically based mathematical model of the wear process (wear equation) is proposed, which allows to determine the linear and weight wear of the babbitt coating surface, formed by any method based on the work of friction, as well as to solve the inverse problem – it allows to find the amount of friction work necessary to carry out the wear of a substance certain amount or required linear wear. For different materials of friction pairs (babbitt insert – SB neck), a method of determining the constants of the wear equation: the largest weight and linear wear, as well as the activation energy of the wear process, which can be criteria for choosing the most rational technology for increasing the durability of the SB, has been developed. To improve the technology of maintenance and repair of equipment used in irrigation systems, a new technology for restoring babbitt coatings has been developed, which can be used for thrust and support SBs. Advanced technology for protecting parts of their elastic couplings from fretting corrosion. At the same time, in order to reduce the wear of the surfaces of flexible elements by up to 50% according to a new method, metal-lubricating materials in the form of paraffin with additives of copper, molybdenum disulfide and graphite are used; to protect the coupling fastening parts, a new method, epilation, is proposed, which allows to reduce the coefficient of friction by 2–3 times. Developed and implemented in production technological recommendations for the manufacture and repair of PU parts economical, energy-saving and ecologically and technogenically safe technologies, protected by 10 patents of Ukraine with a total economic effect of 856 thousand UAH.
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